Skylight construction



2 Sheets-Sheet 1 Filed May 11, 1962 AY/ A AYAYAYAYAYAVAVA -'m INVENToR.RoNALa G. HAWK/Ns jndrus f Star-Ke Arrbnusvs July 6, 1965 R. G. HAwKlNs3,192,659

SKYLIGHT CONSTRUCTION Filed May 11, 1962 2 Sheets-Sheet 2v United StatesPatent() 3,1%,66 SKYLEGHT CNSPUC'HGN Ronald G. Hawkins, Qedarburg, Wis.,assigner to Super Sky Products Company, 1hiensviile, Vlis., acorporation of Wisconsin Fiied May il, i962, Ser. No. 193,975 l@ iairns.(Qi. Sib- 52) The present invention relates generally to skylights andmore specically to skylight-s comprising .a series of interiitting1assemblies designed for installation over the structural framework of abuilding and forming a curved or plane surface.

The recent yarchitectural trend towards the use of larger and some-timescurved skylights, as, for example, in the construction of Ueometric andgeodesic domes, has accentuated problems long connected with the designand Vuse yof skylights and, in some instances, created new problems.

One problem associated with :the use of skylights .arises out ofcondensation of water vapor .on the inside of the skylight in coolweather. If allowed to follow its natur-al course, the condensatecollects lalong the lower portions of each glass pane .of the skylightand eventually falls freely from the skylight into the space below. Thiscondition creates an obvious nuisance tothe people within the buildingand below the skylight as Well .as possibly causing soiling or damage tothe furnishings, equipment or the like within .the structure. The use oflarger skylights has, of course, increased the total condensate andintensified the problem.

It has been proposed in the past to incorporate a drainage system intothe skylight by employing channeled rafters to collect and funnel thecondensate .to suitable condensate receiving means at the skylight edge.Alternately, .it has been attempted to provide a skylight which reducesthe amount of condens-ate laccumulating on .the skylight as for exampleby employing -a double pane .of glass enclosing a dead lair space. inboth cases, however, the end result has been a skylight of unsightly andclumsy appearance, thereby destroying the .architectural unity of theresultant building.

Moreover, these proposed devices in many instances were not suitable,from Aau engineering or economic standpoint, for fabrication in largersizes Aor for application to curved surfaces, particularly where a largenum- .ber of geometrically arranged panes require drainage forsubstantial distances.

In the design of skylights, it is imperative to maintain a closetolerance between .the components of the skylight to insure that ltheglass plates iit correctly within the framework of the skylight. As.this same degree of tolerance is, .of course, not practical to achievein the shell or framework of .the building which is to support theskylight, the lskylight must -be designed with some degree ofadjustability. Where the skylight extends over a substantial area .andis Iinterconnected `at numerous places to the structural framework, arelatively wide degree of adjustment must be provided in the Skylightdesign. Also, in the case of a curved skylight wherein it is necessaryto cant the skylight supports relatively tof one another, means must beprovided for adjusting .the Vangular position of .the skylightcomponents both in plan and in elevation.

insofar as is known, presently existing skylights are not fully capableof adjustment either in degree or kind to meet the various types ofdimensional inaccuracies which may exist. v

The Iabove problems are overcome in the present invention by a skylightconsisting of .a series lof hub assem-V blies which are adapted to besupported on and connected to the framework -or subceil-ing of abuilding and which interconnect with adjacent .assemblies inpredetermined ice manner to provide .a skylight of ,any desired size andin a Wide variety -of configurations.

Each hub .assembly has a hol-low, two-piece hub including .a lower baseand yan upper mating cover with the base adjustably connected to theshell of the building `and with rafters adjustably extend-ing radiallyof the hub and supporting the panes of glass. Each hub of .a given hubassembly is located generally centrally of Ia predetermined number `ofequally spaced surrounding hub-s similarly connected .to the buildingshell. Each of the so-called surrounding hubs, in turn, comprises thecentral hub of .an additional series of .a corresponding number ofsurrounding hubs. This pattern is repeated over the course of theframework of the building or that portion thereof which .is desired tosupport the skylight. Necessary adiustments to the pattern are, ofcourse, made Iat the hubs and at the periphery ofthe skylight.

Each hub is connected to each of the surround-ing hubs -by an extruded.aluminum rafter having .a generally tubular lower section for drainageand a generally iiat preferably pitched glass supporting upper sectionwith a separate .cap section. The rafters de me a series of gener-al--ly triangular openings for each hub .assembly and these openings .areenclosed by individual plates o-r panes of glass lor other sui-tablematerial, such .as synthetic plastic, shaped -in general conformity tothe opening.

The plates of glass are supported yon the upper section of the raftersdefining any one particular opening with the edges of adjacent plates tohe supported on a given rafter in spaced relation to each other and witha longitudinal groove in the upper surface of the rafter section betweenthe edges. rEhe plates .are `clamped against the rafters by separate capsections in the form yof rafter bars disposed lengthwise and directlyIabove the rafters .on the outer surface of .the glass plates. Screwsare inserted .through the rafter bars .and between the spaced edges ofeach pair of adjoining plates for screw threaded engagemen-t withlongitudinal threads formed in the opposite side walls of the groove inthe upper rafter section.

Suitable glazing material or rubber `sealing members lare interposedbetween vthe glass plates .and the rafters vand rafter bars as needed toprovide a water-tight assembly. Similar sealing is provided for thehol-low hub .assemblies at .al-l joints.

The plates of glass are supported generally in the plane between the.adjacent 4hub sections with the vertices of the glass plates beingextended inwardly of the hubs to overlie the upper edge of the base ofthe hub.` Suitable sealing rings .are placed between the hub sections oneither side Aof the overlying portions of the glass plates to seal ltheglass to the hub upon .assembly `of the hub sections and to also sealthe hub sections. The rafter bar ends .are sealed to the hubs by capplates which extend under the upper of the .sealing rings and-also byadjustable connections `for each tube end with the corresponding hub.

The rafters are constructed to collect and drain condensate from theinside surfaces of the skylight. For this purpose iins may be providedon the rafter or on the glazing strip for collecting condensate anddirecting it into a hollow hub, or into the tubular rafter. The lowerportion of each rafter is made tubular and enters the hollow hubs atopposite ends to serve as a part of a tubular net work for drainingcondensate.

Each rafter is secured at the upper end and sealed to the correspondinghub and is loose to freely slide into the hub at the lower end toprovide for necessary expansion and contraction of the rafters withoutdistortion of the skylight. A universal connection preferably in theform of a ball and socket joint secures the rafters and has a pair ofsealing gaskets to close the opening in the hub.

To collect the condensate, the glazing strip beneath and along the edgesof the glass toward which condensate tends to run, is provided with agutter which receives the condensate and conducts the same downwardlyalong the rafter and into the hub at its lower end. If desired therafter may have an extruded gutter on each side and which may catch anyoverliow from the glazing strip gutter should there be any.

The hubs of the skylight in addition to acting as a distribution centerfor water flowing thereto serve as reservoirs in case of a highcondensate runoff rate to prevent the condensate from backing up andoveriowing the troughs along the rafters.

The radial position of the rafters relative to the hubs may be adjustedVwithin limits to permit the rafter to be shifted as needed to adjustfor minor errors in the spacing and location of the hub supports in theskylight system.

A further adjustment is possible to correct errors occurring in theelevation of the supports by adjusting the hub to base relativelyupwardly or downwardly and universally as by a tapered shim.

The invention has found particular adaptation and is herein illustratedas applied to a large dome for a botanical conservatory. In this use itis desired to provide transmission of better than 90% of the light andit is estimated that the present invention provides for transmission ofas high as 94% of the total light.

The skylight of the invention provides a very striking, simpleappearance as is particularly befitting modern day architecture. At thesame time, the skylight provides a very effective condensate collectionand drainage system fully capable of handling momentary high runoffrates as may be required in buildings used for horticultural purposes.

The skylight may be fabricated in any size and shape desired byutilizing any selected number of hub assemblies in any suitablearrangement. The design is such that errors arising in the lay-out ofthe framework of the building may be adjusted for within the usualtolerance limits required in the field.

If desired, the number of rafters connected to any particular hub may bevaried to provide for any selected geometric pattern.

The drawings furnished herewith illustrate the best mode presentlycontemplated of carrying out the invention.

In the drawings: j

FIGURE 1 is an elevation with parts broken away of a horticultural dometo Which the skylight of the invention has found particular application;

FIG. 2 is a vertical section of an individual hub assembly comprisingthe skylight of FIG. 1;

FIG. 3 is a section of rafter and adjacent glass taken along the line 33 of FIG. 2;

FIG. 4 is a section of the rafter and adjacent glass taken along theline 4-4 of FIG. 2; and

FIG. 5 is a section taken on line 5 5 of FIG. 2.

In FIGURE 1 the skylight 1 is appliedover a framework or shell 2 ofconcrete that is constructed to provide a series of vertical, diagonaland horizontal struts 3 intersecting one another in a manner to define anetwork of adjacent geometric patterns preferably defining individualtriangular openings 4 to be covered by individual panes of glass.

The skylight 1 is supported upon the shell 2 by a series of individualhollow hubs 5, each mounted upon an in- A dividual intersection 6 of thestruts 3.

Each hub 5 comprises a bowl-shaped base 7 open at the top, and a cover8. The base 7 is adjustably and universally supported by an internallythreaded column 9 integrally depending from the Vbottom of the bowl andcarried by an upstanding externally threaded post 10 which in turn iswelded as at 11 to a` metal plate 12 embedded in the concreteintersection 6 and secured to the metal re-enforcing in the concrete. Inerecting the skyi light the angular positioning of post 10 is adjustedby means of a tapered shim 13 driven between the post 10 and the plate12, and the height of the bowl 7 is adjusted by threading of the post 10in or out of the column 9, before the post is Welded to plate 12.

The hubs 5 may be of any desirable shape for appearance, the generallyspherical shape shown being illustrative and having some advantage inreducing the amount of shadow cast by the hubs, while providing adequatedepth for collection of water run otf from condensation.

Each hub 5 serves to carry and connect a plurality of rafters 14, theexact number depending upon the pattern for the skylight and thelocation of the hub. For this purpose each hub base 7 is provided withan opening 15 for receiving each of the lower ends of rafters 14 whichdrain into the hub, and an opening 16 for receiving the fastening meansfor each of the upper ends of rafters 14 which drain from the hub.

Each rafter 14 is preferably of extruded aluminum alloy or othersuitable material, and is of uniform section throughout its length.

Referring to FIGS. 3 and 4 the rafters 14 have a vertical web 17 joininga lower closed tubular conduit member 13 and an upper glass support bodymember 19. The conduit member 18 preferably has overflow gutters 20 onopposite sides for conducting condensate into the hub at the lower end.The end of the gutter 20 on the high side of the rafter is plugged atthe fixed end of the rafter by a filler piece 21 which is sealed withsuitable mastic.

The body member 19 for each rafter comprises a flat laterally extendingledge 22 on each side of the rafter for supporting a lower glazing strip23 which in turn supports a corresponding edge portion of a pane ofglass 24.

The lower glazing strip 23 is interlocked with the body member 19 by anysuitable means such as the bead-shaped longitudinal tongue 25 of theglazing strip fitting in a complemental groove 26 in the uppersupporting face of the member.

The glazing strip 23 has an upward flange 27 at its inner edge which isnormally confined between the edge of the glass pane 24 and a centralridge 28 extending longitudinally of member 19 and separating ledges Z2.

The glazing strip 23 on the high side of a diagonal or horizontal rafteris provided with an integral gutter 29 formed at its outer edge andextending beneath the glass 24 to collect condensate therefrom andconduct it downwardly along the rafter. For vertically disposed raftersit is well to have gutters 29 formed on both glazing strips 23 carriedby the rafter.

For the purpose of the skylight illustrated in FIGURE 1 the plane of theupper surface of the ledge 22 on one side of each rafter is disposed ata slight angle to the plane of the upper surface of the ledge 22 on theother side of the rafter to accommodate the necessary angularpositioning of the adjacent panes of glass on the dome.

Each rafter 14 is provided with a rafter cap 30, which is preferably anextruded aluminum body having a flat lower face 31 generallycomplemental to the upper faces of the ledges 22 and a central crown 32to space the cap from ridge 28.

An upper glazing strip 33 is positioned between the face of each side ofcap 30 and the corresponding glass pane 24. A suitable interlock isprovided between the upper glazing strips 33 and cap 30, and maycomprise the beaded tongue 34 extending longitudinally on each strip 33and disposed in the corresponding complemental groove 3S in the face ofthe cap.

The cap 30 is secured to the corresponding rafter 14 by suitable bolts36 spaced longitudinally of the cap and which extend down through it andare threaded into the ridge 2S. For this purpose an upwardly facinggroove 37 is provided in ridge 2S and has serrated side walls tosimulate and receive the threaded bolts at any location along therafter.

Referring to FIGS. 2 and 3, the openings 15 on the upper side of hubbase 7 are sufficiently large to receive the conduit 18 and gutters 2dof the lower end of the corresponding rafters. For this purpose eachrafter web 17 is cut away at the lower end of the rafter to provide aslot 38 to receive the upper inwardly hanged edge of base 7. The bodymember 19 extends inwardly over the top of base 7 and the conduit 18extends into the base through the corresponding opening 15.

The openings 16 on the lower side of the hub base 7 are generallycircular and receive the body of corresponding bolts 39 which arethreaded into the conduits 1S of the upper ends of the correspondingrafters. For this purpose the conduit 18 and web 17 of the upper end ofeach rafter is cut away so that the body member 19 may extend inwardlyover the top inwardly flanged edge of base 7.

The inner end 40 of each bolt 39 is spherical and bears universallyagainst a compression collar 41 extending through opening 16 and havinga ange engaging the outside of the base 7. A compression nut 42 isthreaded onto the inner end of collar 4T. and has an inward flange 43confining the spherical end 4t) of bolt 39 between it and the collar 41.Suitable sealing gaskets 44 and 45 are provided between flange 43 andspherical end ttl and between nut 42 and the inner wall of the base 7,respectively, to prevent leakage around the fastening.

The hub cover S for each hub is of dome-shape and is sealed upon theglass panes 24 by means of a circular hub gasket 46 of suitable glazingmaterial. The cover S is held in place, clamping the glass 24 andrafters in position, by a connecting rod 47 threaded into a tappedopening in an upstanding boss 4S in the bottom of base 7, and a nut 49threaded upon the upper end of the rod and received in a recess 50 inthe cover so that the nut is flush with the cover on the outside.

When the nut 49 is tight the cover 8 clamps the glass 24 and rafters 14tightly in place, and effects a seal across the top of the juncturebetween the panes of glass at the hub 5.

In order to complete the seal betwen two adjacent panes of glass as theyenter beneath gasket 46, a cap end 51 is applied over the end of therafter cap 30 and has a fiat tongue 52 which extends under the gasket46. One of the bolts 36 secures the cap end 51 in place.

In service the skylight is so constructed that expansion and contractionby temperature differences and wind pressures are provided for. Eachrafter is secured only at one end and is free to expand or contractlongitudinally as may be required. The rafters provide means to collectall condensate and to conduct it to the closed drainage system comprisedof the hollow hubs 5 and the conduit members 18 of the rafters.

Various modes of carrying out the present invention are contemplated asbeing within the scope of the following claims particularly pointing outand distinctly claiming the subject matter regarded as the nature of theinvention.

I claim:

1. A dome skylight construction comprising a substantial number ofskylight panes arranged in spaced edgeto-edge relation with adjacentpanes disposed in angularly related planes, said panes being disposed ina predetermined pattern thus providing a plurality of spaced hub centersadjacent the corners of said panes, individual rafters disposed betweenthe edges of adjacent panes, hub members at said hub centers andcarrying the ends of said rafters, means securing at least one end ofeach rafter to a corresponding hub member, and means beneath andsupporting individual hub members thereby supporting said dome skylightconstruction.

2. The construction of claim 1 and means separately and adjustablysecuring each hub member to said last named support means therebysupporting the skylight rigidly and substantially free of the necessarydimensional tolerance of the supporting Structure.

3. The construction of claim 1 in which said hub members are hollow withadjacent hubs disposed at different heights and said rafters comprise inpart hollow tubular conduit means for draining water from upper hubs tolower hubs and to discharge, and means on each rafter to collectcondensate and discharge the same into the hubs.

4. The construction of claim 1 in which said rafter securing means is atthe upper end of each rafter, and the lower end of each rafter extendsfreely into a corresponding hub, said rafters being individually free toexpand and contract longitudinally with temperature changes.

5. The construction of claim 1 in which each hub member comprises a baseportion and a cap portion and the skylight panes extend to between saidportions, and means clamping and sealing said cap portion upon the topof the skylight panes.

6. The construction of claim 5 in which said clamping means comprises astud bolt connecting said base portion and said cap portion centrally.

7. The construction of claim 3 in which each rafter is of extrudedaluminum alloy and comprises a closed tubular base, a vertical web, panesupporting flanges at the upper edge of said web, and a cap for therafter.

8. A skylight construction comprising a plurality of spacedsubstantially closed hollow hubs individually supported at spacedintervals and at different elevations, tubular rafters radiating fromeach hub and extending to adjacent hubs and communicating with theinterior thereof, inclined gutter means carried by selected rafters,said gutter means communicating with the interior of the hubs at thelower ends of said gutter means, and skylight panes supported in spacededge to edge relation upon said rafters above said gutter means, wherebycondensation is drained from said panes into said gutters and fromthence into said hollow hubs and then from said hubs through saidtubular rafters and corresponding lower hubs and rafters to a point ofdischarge.

9. The construction of claim 8 and means securing each rafter to itsuppermost hub in substantially sealed relation thereto to receivedrainage water therefrom, the lower end of each said rafter extendingfreely into its corresponding lower hub to deliver drainage waterthereto.

10. The construction of claim 9 and openings in said hubs to receive thecorresponding ends of said rafters with a tolerance variation in angularadjustment for the rafters, said openings for the upper ends of therafters receiving a sealed coupling having a tubular member threaded tothe tubular portion of the rafter, and said openings for the lower endsof the rafters receiving both the tubular portion of the rafter and thegutter thereon.

References Cited by the Examiner UNITED STATES PATENTS 1,931,750 10/33Blaski 50-201 1,968,125 7/34 Cibulas 50-207 2,537,216 1/51 Paix 50-2072,682,235 6/54 Fuller 50-52 2,978,074 4/61 Schmidt 50-52 3,002,590 10/61Hannoosh et al. 5052 FOREIGN PATENTS 370,383 4/ 32 Great Britain.

HENRY C. SUTHERLAND, Primary Examiner.

JACOB L. NACKENOFF, Examiner.

1. A DOME SKYLIGHT CONSTRUCTION COMPRISING A SUBSTANTIAL NUMBER OFSKYLIGHT PANES ARRANGED IN SPACED EDGETO-EDGE RELATION WITH ADJACENTPANES DISPOSED IN ANGULARLY RELATED PLANES, SAID PANES BEING DISPOSED INA PREDETERMINED PATTERN THUS PROVIDING A PLURALITY OF SPACED HUB CENTERSADJACENT THE CORNERS OF SAID PANES, INDIVIDUAL RAFTERS DISPOSED BETWEENTHE EDGES OF ADJACENT PANES, HUB MEMBERS AT SAID HUB CENTERS ANDCARRYING THE ENDS OF SAID RAFTERS, MEANS SECURING AT LEAST ONE END OFEACH RAFTER TO A CORRESPONDING HUB MEMBER, AND MEANS